Process of manufacturing smooth surface floor coverings



Patented May 26, 1931 UNITED STATES PATENT OFFICE RALPH G. J AGKSON, 0F WOODIBURY, JERSEY No Drawing. Application filed June 1,

This invention relates to the manufacture of smooth-surfaced floor coverings and more partlcularly to the coloring of wear layers of floor coverings-to decorate the same. 1

, layer composition to a suitable support, and

when in a solid substantially finished condition, impregnating the layer with coloring agents. By a solid, substantially finished condition is meant, the condition the floor covering is in when the paint or linoleum Wear layer is substantially free from stickiness and when, if nothing further were done to it except to permit it to dry more thoroughly, it would be in proper condition for use as a wear surface.

Heretofore it has been the practice to' introduce colorings into the compositions used forwear surfaces, such as linoleum or paints, before the application of the wear layer composition to a fibrous support such as burlap or felt. Where paint is used as a wear layer,

' and designs are produced by applying to the surface of the solid material the various colored paints to obtain the decoration desired, it usually results in the formation of ridges and, generally, an uneven surface. In the use of paint, when a thicker wear layer is desired, it is impractical to super-impose the design coats of paint, due to the difiicluty of accurate super-imposition. In the use of linoleum compositions, certain disadvantages arise where each color is applied as an individual section and in this case there is a lack of homogeneity and hence a decrease in strength, In addition, shading effects are not successfully obtained and generally the 192?. Serial No. 195,872.

accurate reproduction of certain designs is almost impossible. a

In carrying out the process of this invention the first step is, to apply any one of the fiowable compositions which are usually employed as wear layers in floor coverings, to a support such as felt or burlap. An oil paint, water paint, or linoleum composition may be used as a wear layer, providing a continuous even surface over the whole area. In some cases a wear body, if it has suflicient tensile strength, may be made up without the use of a support. A number of coats of paint may be applied to obtain the desired thickness, or in the case of linoleum, the linseed oil, cork and Wood flour mixture is spread on in a single layer.

The various different layers mentioned, are then solidified by permitting them to dry or by passing them between suitable pressure rollers. In other words the wear layer is brought to a point where it is substantially in a finished condition. Preferably, this point is not further than that at which the wear layer is no longer sticky when handled.

The wear layer, which is preferably of a neutral color when applied, is then ready to be decorated. This may be done by forcing suitable coloring agents into the layers under pressure. The coloring agents are preferably soluble dyes or colloidal paints. When a dye is used, it is dissolved in a solvent which is also a solvent for the binding agent employed in the wear layer. The common solvent aids penetration. In colloidal paints the pigment particles are ultra-microscopic in size and therefore will be easily forced into the minute pores of a solid wear layer. In either case the color is distributed throughout the thickness of the layer.

The following is a specific example of the process: A paint providing a neutral color wear coat is spread on' a support.

This paint is well dried, but it is generally desirable to apply the coloring agent before phere with solvent vapors.

all the solvent has evaporated from the paint. The design colors are then applied in zones restricted to conform to the detail of the de sign from suitable blocks, in a manner similar to that by which paper is covered with colored designs. Where a paint of the above composition has been used, the following is an example of a dye solution:

Parts by weight Malachite green 1 Butyl acetate 2O Nitrocellulose l Castor oil A;

dye may be aided by heating the dye solution to reduce its viscosity. The evaporation rate of the dye solvent may be reduced by saturating the drying atmos- In this way the dye is given a longer time in which to distribute itself.

Where a linseed oil paint is used as a wear coat, the following is an example of a dye solution employed Parts by weight Induhne Kerosene n Aluminum stearate may be added to give body to the dye solution. 'It retards solvent evaporation and thus aids penetration.

By the foregoing methods, a floor covering is produced having a smoother surface than heretofore obtainable since the wear surface is a homogeneous layer, and not a layer consisting of different colored parts applied at different times or a layer on the surface of which the various colors are placed, thereby producing ridges and hollows. The surface as a unit possesses great strength since it is homogeneous, and not made up of different sections. A very thick wear surface is obtained by applying a number of coats of paint and the color may be made to penetrate them.

Shading effects may be obtained just as they are obtained on paper, and by overlapping the colors, six or eight colors may be obtained by applying only four original colors.

By using transparent colors, lithographing effects may be obtained, thus making possible designs of much greater beauty than those possible when each color or shade isapplied as a different section of the wear surface.

What I claim is:

1. A process of making smootlasurfaced floor coverings which process consists in coating a support with a continuous layer of a fiowable composition, solidifying the said composition to substantially that stage at which it is free from stickiness whenhandled and suitable for use as a wear surface of the said floor coverings and its surface is smooth, and then at that stage and before further drying coloring the body of the said substantially finished layer by impregnating it with a coloring agent which decorates and leaves a continuous smooth surface substantially identical with said wear surface and substantially free from any additi'onai surface layer.

2. A process of making smoothsurfaced floor coverings which process consists in coating a support with a continuous layer of a flowable composition, solidifying the said composition to substantially that stage at which it is free' from stickiness when handled and suitable for use as a wear surface of the said floor coverings and its surface is smooth, and then at that stage decorating the said layer by impregnating it with a dye which decorates and leaves a continuous smooth surface substantially identical with said wear surface and substantially free from any additional surface layer.

3. A process of making smooth-surfaced fioor coverings which process consists in coating a support with a wear layer of a flowable composition including a binding medium, solidifying the said composition to substantially that stage at which it is suitable for use as a wear surface of the said floor coverings and its surface is smooth, and at that stage and before further drying impregnating the said layer with dyeing agents applied to restricted zones, the dyeing agents being in solution in a solvent which is a solvent for the said binding medium, the effect of said dyeing agents resulting in the decoration of the smooth-surface free from any additional thickness of wear layer.

4. A process of making smooth-surfaced floor coverings which process consists in coating a support with a wear layer of a flowable composition including a binding medium, solidifying the said composition to substantially that stage at whichit is suitable for use as a wear surface of the said floor coverings and its surface issmooth, and at that stage and before further drying impregnating the said layer with dyeing agents dissolved in a solvent which is a solvent for the said binding medium, said dyeing agents resulting in the decoration of the smooth surface free from any additional thickness of wear layer,

5. A process of making smooth-surfaced floor coverings, which process consists in coating a support with a smooth surface wear layenof a composition including linseed oil, and impregnating said layer with dyeing agents dissolved in a solvent which is a solvent for the said linseed oil, said dyeing agents resulting in the decoration of the smooth surface free from any additional thickness of wear layer.

6. A process for making smooth-urfaveds floor coverings, which process consists in coating 'a support with a smooth surface wear layer of a composition including linseed oil, and treating said layer with a preparation including induline and kerosene, said dyeing agents resulting in the decoration of the smooth surface free from any additional thickness of wear layer.

6. A process for making smooth-surfaced floor coverings, which process consists in coating a support with a smooth surface Wear layer of .a composition including linseed oil, and treating said layer with a preparation including induline and kerosene and aluminum stearate, said dyeing agents resulting in the decoration of the smooth surface free from any additional thickness of wear layer.

In testimony whereof I aifix my signature.

RALPH G. JACKSON. 

